That sounds pretty interesting. Being a 3D modeler I'm trying to create my own templates, then unfold them in Pepakura Designer, and I was thinking that this should work... I do try to factor in the 10mm thickness of the foam in my modeling, simplify stuff when necessary, watch for angled cuts and so on. I'm also fitting all the parts to a sort of a 3D scan of myself, hoping to avoid any scaling problems.
But I have only started about 2 weeks ago and haven't finished anything yet, so now I'm kinda worried if it's going to work in practice